ABCD PUMPS - Model 2020: User and Maintenance Manual

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ABCD PUMPS - Model 2020

User and Maintenance Manual

Sample of Technical Documentation

• Technical Description
• Usage and Maintenance Instructions
• Parts Catalogue
This page is intentionally left blank.

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User and Maintenance Manual

Table of contents

Introduction to Model 2020 pump ......................................................................... 1


[Image] - Model 2020 pump................................................................................................. 1
Highlights............................................................................................................................ 1
[Image] - Typical pump installation ...................................................................................... 2
Features ......................................................................................................................... 2
Details of pump................................................................................................................... 3
Pump casing................................................................................................................... 3
Impeller........................................................................................................................... 3
Shaft ............................................................................................................................... 3
Stuffing box .................................................................................................................... 3
Bearing ........................................................................................................................... 3
Lubrication...................................................................................................................... 3
Drive ............................................................................................................................... 4
Application.......................................................................................................................... 4
Animation............................................................................................................................ 4
Delivery options.................................................................................................................. 4
Basic pump..................................................................................................................... 4
[Image] - Basic pump........................................................................................................... 5
Integrated pump-set ....................................................................................................... 5
[Image] - Integrated pump and motor combination.............................................................. 6
[Image] - Parts of the pump-set ........................................................................................... 7
Dimensions......................................................................................................................... 7
Installation............................................................................................................... 9
Order options...................................................................................................................... 9
Installation of basic pump............................................................................................... 9
[Image] - Concrete platform ................................................................................................. 9
[Image] - Foundation plate................................................................................................. 10
[Image] - Inserting anchor bolts ......................................................................................... 10
[Image] - Mounting the complete pump on concrete platform............................................ 11
[Image] - Fitting inlet and outlet flanges with gaskets ........................................................ 12
[Image] - Non-return check valve at the bottom of the inlet pipe ....................................... 13
[Image] - Wiring the motor through cable gland................................................................. 14
Installation of integrated pump-set ............................................................................... 14
Using the pump-set .............................................................................................. 15
Starting the pump ............................................................................................................. 15
Stopping the pump ........................................................................................................... 15
Pre-starting checklist ........................................................................................................ 15

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User and Maintenance Manual

During running checklist ................................................................................................... 16


Post-starting checklist....................................................................................................... 16
Priming the pump ............................................................................................................. 16
[Image] - Priming the pump 1/3.......................................................................................... 17
[Image] - Priming the pump 2/3.......................................................................................... 18
[Image] - Priming the pump 3/3.......................................................................................... 18
Draining the pump ............................................................................................................ 19
[Image] - Draining the pump .............................................................................................. 19
Maintenance.......................................................................................................... 21
Daily maintenance............................................................................................................ 21
Maintenance, every three months .................................................................................... 22
Annual maintenance......................................................................................................... 22
Spare parts............................................................................................................ 23
Views................................................................................................................................ 23

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User and Maintenance Manual

Glossary

Click on number for navigating to the page.

B
Bearing lantern
Assembly that keeps contaminants and liquids out of the stuffing box to protect the bearings. - 3
C
Cable glands
Detachable devices that clamps over cable exteriors as it enters enclosure for sealing against
ingress of dirt/moisture and avoid mechanical damage to the cable. - - - - - - - - - - - - - 6
Cavitation
Bubbles formed due to low pressure around the pump impeller. These bubbles can cause damage
to the impeller and/or the pump housing. - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
Circuit breaker
Electrical switch that automatically disconnects supply due to an electrical overload. - - - - - 15
D
Dynamic balancing
Balancing of a rotating object to mitigate forces in direction other than the axis of rotation to avoid
the vibrations and uneven running. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3
E
End suction
Centrifugal pump with casing having suction at one end and discharge at the top. - - - - - - - 1
F
Fastener
Hardware device for mechanically joining or affixing two or more assemblies, like bolts, nuts,
washers, etc. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
Flange
An external or internal ridge to help connect sections of pipes. - - - - - - - - - - - - - - - - 6
Foundation bolt
High tensile bolts used to connect equipment to the concrete foundations. - - - - - - - - - - 6
G
Gasket
Seal made from softer material to fill the space between two or more mating surfaces to prevent
leakages. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
Grouting
Filling space in a hole with bolt with cement to seal the gap and strengthen the joint. - - - - - 6
H
Head
Height to which a pump can raise water. - - - - - - - - - - - - - - - - - - - - - - - - - - - 1

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User and Maintenance Manual

High-tensile fastener
These fasteners are made from carbon steel or tempered alloy steel to provide an increased tensile
strength that allows stronger joints. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11
I
Impeller
Rotating part of a centrifugal pump, that moves a fluid by rotation. - - - - - - - - - - - - - - 1
L
Lovejoy
Three-piece couplings with spider-shaped cushion between two hubs that reduces shock and
allows minor shaft misalignment. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
N
Non-return check valve
A valve that allows only one-way movement of liquid and blocks the return flow. - - - - - - - 12
Nylock
A nut with a nylon-insert to increase friction on the screw thread and prevent becoming loose due
to vibration. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11
P
Packing
Flexible or rope-like material inside the stuffing box to improve sealing of the shaft. - - - - - - 21
Prime
Filling the pump body with liquid prior to starting. Priming the pump allows best liquid transfer
efficiency and avoids dry running that damages the pump seals. - - - - - - - - - - - - - - - 14
R
RPM
Revolutions per minute, unit of a shaft’s rotation speed. - - - - - - - - - - - - - - - - - - - 2
S
Seal
Annular element around a rotating shaft to prevent loss of pressure on one side of the seal. - - 1
Spring-washer
A washed with spring-like deformation to prevent loosening of fasteners due to vibrations. - - 11
Stencil
Sheet with holes for transferring marking to the underlying surface. - - - - - - - - - - - - - - 6
Stuffing box
Assembly housing a seal that prevents leakage of liquid on a rotating shaft. - - - - - - - - - - 3
T
TEFC
Totally enclosed fan cooled, a type of electric motor. - - - - - - - - - - - - - - - - - - - - - 5
V
Volute
Casing of a centrifugal pump receiving liquid from the impeller. - - - - - - - - - - - - - - - - 1

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Introduction to Model 2020 pump

Model 2020 pump

Highlights

Model 2020 pump is an end suction, single stage, horizontal shaft,


volute type pump.

ABCD Pumps’ Model 2020 lifts clear and mildly turbid water over a
maximum head of 30 meters.

• Helped by an advanced anti-cavitation design, the volute casing and


impeller are designed for high efficiency and long life.

• The pump seals are made from a specially formulated alloy for a
long service life and ability to withstand high volute pressures.

• The pump can handle water over a wide temperature range to suit
varied applications.

• With best in class engineering, Model 2020 pump is backed by a


responsive 24X7 service and spares network to ensure that your
pump is always available for continuous duty.

Highlights www.magnaproduce.com 1
User and Maintenance Manual

Typical pump installation

Features

Parameter Value

Head 30 meters

Delivery size 100 mm

Capacity Up to 7000 m3/hour


Temperature 0 °C (without ice formation) to 90 °C

Motor 3.7 kW, 415 VAC, 3 phase

Weight Only pump, 65 kilograms

Volume 10% smaller than equivalent pumps

Nominal speed 1500 RPM

Direction of rotation Clockwise, viewed from driving enda

• For models MF 17 1.2 - 20, MF 55-60, MF


60-65 pumps drill flanges as per BS10,
Flange size table D.

• For all other models, drill flanges as per


BSEN 1092, flat face PN.
a. The direction of rotation is marked on the bearing lantern.

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User and Maintenance Manual

Details of pump

Pump casing

• Horizontal and vertical end suction.

• High efficiency volute type pump with top, side, and 45 degrees
orientations.

• Integral casting of delivery flange and supporting feet with the


pump casing.

• Precision dynamic balancing for rotating parts.

Impeller

• Standard impeller with enclosed type design option for pumping


clean liquid.

• Optional impeller with non-clog or semi-open design option for


pumping liquid with suspended solids.

• Hydraulic balancing by equalizing holes and back vanes.

Shaft

• Made from high-tensile steel.

• Accurately ground with complex profile.

• Precision alignment of the shaft with the bearings holder.

Stuffing box

• Normal temperature version: Standard stuffing box with polymer


seals for handling liquid temperatures up to 65°C.

• High temperature version: Optional stuffing box with metal based


mechanical seals for handling liquids with temperature up to 90°C.

Bearing

• Deep groove ball bearing and thrust bearing, mounted in a carefully


designed bearing lantern.

Lubrication

• Normal temperature version: Grease lubrication through grease


nipple in the bearing holder.

Details of pump www.magnaproduce.com 3


User and Maintenance Manual

• High temperature version: 20W40 mineral oil through an external


lubrication cup and an adjustable drip-feed orifice.

Drive

• Direct drive through a Lovejoy rubber bushed coupling.

• Powered by electric motor or diesel engine.

Application

• The applications for model 2020 pump include:

• Water supply schemes

• Drainage and storm-water handling

• Irrigation systems

• Air-conditioning systems

• Industrial processes

Animation

 Note
Animation will play only in the online version of this manual.

Delivery options

Basic pump

In this option, we offer only the basic model 2020 pump. You have to
do the following tasks to make a functional pump-set. You may use the

4 www.magnaproduce.com Application
User and Maintenance Manual

following drawing for manufacturing the base frame that mounts the
pump and motor: “Foundation plate” on page 10

Basic pump
To commission a basic pump, you have to select and install the
following sub-assemblies on the foundation plate:

• Motor

• Coupling

• Inlet and outlet flange

• Gasket for the flange

• Fasteners and shims

Integrated pump-set

To save time and efforts for end user, model 2020 pump is available as
a complete ready-to-use module with factory integrated and aligned
sub-assemblies. The combination is supplied with comprehensive
performance test certificate and integrated warranty.
This combination consists of:

• Model 2020 pump

• Siemens or Crompton make 3.7 kW, 415 VAC, 3 phase TEFC motor

Delivery options www.magnaproduce.com 5


User and Maintenance Manual

• ‘Lovejoy’ coupling between pump and motor

• Mounting bracket for pump and motor

• Inlet and outlet flanges

• Inlet and outlet flange gaskets

• Set of suitable fasteners for mounting pump assembly and flanges

• Foundation bolts and grouting compound

Integrated pump and motor combination


• Cable glands for motor junction box

• Stencil to accurately locate holes for foundation bolts

• Suitable hand tools required for installation

Not included with the integrated pump-set option:

◊ Inlet and outlet pipe

◊ Non-return check valve

◊ Priming arrangement

◊ Electrical panel

◊ Electrical wiring

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User and Maintenance Manual

Parts of the pump-set


If required, our service team can arrange these parts and install them
for you on a payment basis.

Dimensions

This drawing shows the dimension of pump from various views.

Dimensions www.magnaproduce.com 7
User and Maintenance Manual












[+ROHV




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Installation

 Note
Only trained and qualified technicians should install the pump.

Order options

You have two options while placing an order:

• Order only the basic model 2020 pump. See “Basic pump” on
page 5.

• Order the factory assembled integrated pump-set. See “Integrated


pump and motor combination” on page 6.

Installation of basic pump






 [+ROHV








Concrete platform

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User and Maintenance Manual

1. Construct a concrete platform of 1200 X 800 X 160 mm adjacent to


the water pick-up point. Ensure the platform capacity ≥ 250 kgs.
Level the platform to ± 1 mm. See “Concrete platform” on page 9.






 [+ROHV


 [+ROHV







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  [+ROHV

 
 









 

Foundation plate
2. Drill and insert M20 anchor bolts to the concrete for mounting the
foundation plate. Use grouting compound for securing anchor bolts
to the concrete.

Inserting anchor bolts

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User and Maintenance Manual

3. Fabricate the foundation plate for mounting pump and motor. Use
the drawing of “Foundation plate” on page 10 as a reference.

4. Mount the pump and motor on the foundation plate.

5. Align the motor shaft with the pump shaft using shims within ± 0.5
mm.

6. Add and tighten a ‘Lovejoy’ coupling between the motor and pump
shaft.

7. Mount the foundation plate complete with pump, motor, and


coupling on the concrete platform.

Mounting the complete pump on concrete platform

 Note
Use high-tensile fasteners. Use plain washers to spread the force. Use
spring-washers to ensure fastener tightness under service conditions.
As an alternate to spring-washers, use Nylock® nuts with plain
washers.

8. Tighten the anchor bolts to 300 Nm torque.

 Note
Use high-tensile fasteners with Nylock® nuts.

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User and Maintenance Manual

9. Couple the inlet and outlet pipes to the flanges. Use gaskets
between the pump and pipe flanges. Tighten the fasteners to 125
Nm torque.

Fitting inlet and outlet flanges with gaskets

 Note
If the water level is below the inlet flange, fit a non-return check valve
at the bottom of inlet pipe.

 Note
Ensure that the inlet pipe has provisions to connect external water
supply to prime the pump, prior to starting.

10. Make electrical connections through properly rated switch gear


and protective devices. Ensure that the pump is protected against
loss of phase, reverse phase, under-voltage, over-voltage,
overloads, and dry-running.
11. Route the adequately sized cable rated for the installation
environment. Ensure that through all holes, the cable is fitted with
correct size of gland.

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User and Maintenance Manual

Non-return check valve at the bottom of the inlet pipe


12. Ensure that the motor rotates the pump in the marked direction. If
the pump rotates in reverse direction, isolate supply from source
and interchange any two of the phases.

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User and Maintenance Manual

Wiring the motor through cable gland

 Note
Power the pump only for a second to check the direction of rotation.

13. Prime the pump and check for leakages before powering the
motor. See “Priming the pump” on page 16.

Installation of integrated pump-set

Installation of integrated pump-set is similar to that of the basic pump,


except for skipping steps 3, 4, 5, and 6 from the previous instructions.
See “Installation of basic pump” on page 9.

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Using the pump-set
In normal use, the pump-set starts working as soon as the motor is
switched on.

 Note
Only authorized and trained personnel should operate and maintain
the pump.

Starting the pump

1. Connect the incoming supply to the control panel by closing the


circuit breaker.
2. Press the Start switch on the control panel to start the pump.
3. Wait for the pump speed to stabilize.
4. Monitor the electrical parameters for balanced load current on all
phases.

Stopping the pump

1. Press the Stop switch on the control panel to stop the pump.
2. Disconnect the incoming supply to the control panel by opening the
circuit breaker.

Pre-starting checklist

 Note
The control panel should have protection for loss of phase, reversal of
phase, under-voltage, over-voltage, overloads, and dry-running.

Check the following points before starting the pump:


1. Adequate water level in the sump tank.
2. Presence of 3 phase supply within accepted limits.
3. Pump is in a primed condition.

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User and Maintenance Manual

4. All guards are installed, control panel doors are closed, all inlet and
outlet valves are in the open position.

 Note
Pump seals and casing will get damaged if it runs with closed inlet and
outlet valves.

5. Pump, motor, and coupling do have any obstruction.

During running checklist

1. Ensure that the pump is running smoothly without any unusual


sounds and vibrations.

2. Check water pressure on the delivery side. Ensure that the water
pressure does not fluctuate excessively.

3. Check for current consumption in each phase and confirm that the
three phase current readings are nearly the same.

4. Check that motor has a flow of cooling air over its frame and that it
is not heating excessively.

Post-starting checklist

Perform the first procedure if the pump does not run regularly, or is
started after a long time, or if you suspect that the non-return check
valve at the bottom of the inlet pipe is defective.

1. After starting the pump, open the priming water inlet valve on the
incoming flange.

◊ Ensure that the water sprays under pressure from the


priming inlet. The spray confirms that the pump is
developing positive pressure.

2. Close the priming inlet valve.

3. While the pump is running, observe for any unusual sound or


vibration.

4. Check the motor current in all three phases and ensure that the
load is balanced.

Priming the pump

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User and Maintenance Manual

Priming the pump 1/3


To work efficiently, the pump casing has to be full of water before the
impeller starts rotating.

 Note
The rotor seals will get permanently damaged if the pump runs
without water. Prime the pump only when it is not running.

1. Open priming bleed bolt [1] on the pump casing.


2. Connect an external source of water to the priming inlet [2].
3. Open the priming inlet valve [3].
◊ The external water fills up the inlet pipe and the pump
casing [4].

◊ Water overflows from the bleed hole in the casing [5].

Priming the pump www.magnaproduce.com 17


User and Maintenance Manual

Priming the pump 2/3

Priming the pump 3/3

18 www.magnaproduce.com Priming the pump


User and Maintenance Manual

4. Close and secure the priming bleed bolt trapping the water in the
pump casing. [6]
5. Close the priming inlet valve [7].
6. Stop and disconnect the external source of water from the priming
inlet [8].
7. Your pump is now primed and ready to move water from lower
levels to full-head heights.

Draining the pump

You may need to drain the pump casing before doing maintenance on
bearings or the seals.

 Note
Drain the pump only when it is not running.

1. Close inlet valve, if fitted.

 Note
Be prepared to collect the water that may flow from pump casing after
you open the drain hole.

Draining the pump

Draining the pump www.magnaproduce.com 19


User and Maintenance Manual

2. Close the outlet valve, if fitted.


3. Open the drain bolt [1].
4. Close the drain bolt after pump casing is empty of water.
5. Open the inlet and outlet valves. Prime the pump. Run to check that
the pump casing does not have any leakages.

20 www.magnaproduce.com Draining the pump


Maintenance
Perform the following tasks whenever you check the pump during
routine inspections:
• Check the level and condition of the lube oil through the sight glass
on the bearing frame.

• Check for unusual noise, vibration, and bearing temperatures.

• Check the pump casing, flanges, and piping for leaks.

• Monitor the vibrations, analyse, and rectify the reasons.

• Inspect the discharge pressure.

• Inspect the bearing and seal temperatures.

• Check the seals and stuffing box for leaks.

• Ensure that there are no leaks from the mechanical seal.

• Adjust or replace the packing in the stuffing box if you notice


excessive leaking.

Daily maintenance

Perform the following tasks daily:


• Clean bearing bracket, inspect for leakage of oil or grease.

• Check that pump’s drain plug is tightly closed.

• Inspect suction and discharge flanges for any leaks.

• Inspect pump casing for any damage.

• Inspect the seal, paying attention to the lip for cuts or irregularities.

• Check the coupling for damage and bolts for tightness.

 Note
Check coupling and bolts only if the pump is not running.

• Ensure that the coupling guard is present and secure to base plate.

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User and Maintenance Manual

• Check the alignment and tightness of pump mounting bolts.

Maintenance, every three months

Perform the following tasks every three months:

• Check that the foundation bolts are tight.

• Check the mechanical seal if the pump has sitting idle for some
time. Replace if required.

• Top-up grease or oil for the bearings via external lubrication cup or
grease nipple. Fill oil in cup to the maximum marking. Push grease
into the nipple via a grease gun until the operating handle becomes
tough to move.

• Lubricate the bearings more frequently if the pump runs


continuously or if the ambient temperature is > 45 °C.

• Check the shaft alignment and call ABCD service if movement is >
100 uM.

Annual maintenance

Perform the following inspections once each year:

• Check the pump capacity.

• Check the pump pressure.

• Check the pump power.

If the pump performance does not satisfy your process requirements,


and the process requirements have not changed, then do the following:

1. Disassemble the pump.

2. Inspect the pump.

3. Replace worn parts.

 Note
If in doubt, always consult the ABCD Pumps’ service department.

22 www.magnaproduce.com Maintenance, every


Spare parts
We offer the complete spare parts of the model 2020 pump. In case you
order the integrated pump-set, the motor and coupling is available as
complete assemblies.

For spares and service of the motor or coupling, inform their nearest
authorized technical partners, whose details are available your local
ABCD Pumps representatives.

Views

The following pages contain illustrated spare list of the basic pump and
the integrated pump-set.

 Note
The active links between parts in the images and tabulated list will
display only in the online manual.

• Go to: “Integrated pump-set” on page 24.

• Go to: “Model 2020 pump, intake flange view” on page 25.


• Go to: “Model 2020 pump, driving shaft end view” on page 26.

Views www.magnaproduce.com 23
User and Maintenance Manual

Integrated pump-set

BOM ID Description Qty


1 Model 2020 pump 1
2 3.7 kW TEFC motor 1
3 Coupling, pump end 1
4 Coupling, motor end 1
5 Bolt M10 4
7 Washer M10 8
8 Nut M16 2
9 Spring washer 16 Ø 2
10 Washer 16 Ø 4
11 Bolt M16 2
12 Spring Washer Dia 18 20
16 13 Nut M18 20
14 Washer Dia 18 mm 40
15 Nut M10 4
17
16 M18 bolt 20
17 Flange, delivery pipe 1
18 18 Gasket, delivery pipe flange 1
19 Flange, inlet pipe 1
20 Gasket, inlet pipe flange 1
14

4 2
12 3
1

13

15

7
11
16 5
10
14
9
14

12 8

13
16 14 19 20 12 14 13

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User and Maintenance Manual

Model 2020 pump, intake flange view

BOM ID Description Qty


1 Impeller Nut 1
2 Pump Casing 1
3 Sealing Ring 1 8
4 Impeller 1
7
5 Sealing Plate 1
6 Inner Seal 1 6
7 Outer Seal 1
8 Cover Bolt 12 5

Views www.magnaproduce.com 25
User and Maintenance Manual

Model 2020 pump, driving shaft end view

BOM ID Description Qty


1 Bolt, Bearing Cover 4
2 Bearing Cover 1
3 Grease Nipple 1
4 Bearing Holder 1
5 Outer Bearing 1
6 Driving Shaft 1
7 Inner Bearing 1 7

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User and Maintenance Manual

Index

A
Animation .............................................................................................................................4
Application ............................................................................................................................4
D
Delivery options
Basic pump ....................................................................................................................4
Integrated pump-set .......................................................................................................5
Details of pump
Bearing ...........................................................................................................................3
Drive ...............................................................................................................................4
Impeller ..........................................................................................................................3
Lubrication .....................................................................................................................3
Pump casing ..................................................................................................................3
Shaft ...............................................................................................................................3
Stuffing box ....................................................................................................................3
Dimensions ...........................................................................................................................7
Draining the pump ..............................................................................................................19
H
Highlights
Features .........................................................................................................................2
I
Installation
Installation of basic pump ..............................................................................................9
Installation of integrated pump-set ...............................................................................14
Order options .................................................................................................................9
M
Maintenance
Annual maintenance ....................................................................................................22
Daily maintenance .......................................................................................................21
Maintenance, every three months ................................................................................22
P
Priming the pump ...............................................................................................................16
S
Spare parts .........................................................................................................................23
Views ...........................................................................................................................23

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User and Maintenance Manual

U
Using the pump-set
During running checklist ...............................................................................................16
Post-starting checklist ..................................................................................................16
Pre-starting checklist ....................................................................................................15
Starting the pump .........................................................................................................15
Stopping the pump .......................................................................................................15

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